Page 265 - TPM A Route to World-Class Performance

Case studies 239

Norman’s suggestion, the vice was set down into the bench so that he can
slide, instead of lift, the casting into it - an improvement costing €20 which
has had a sigruficant impact on health and safety by improving the ergonomics
of the process.

PGM core machine
The PGM core manufacturing machine moulds resin-enriched sand which is
then used in the casting process. Prior to TPM, there were chronic losses in
the precess, including unplanned downtime, quality and excessive waste.
A series of more than twenty improvements have been made by the TPM
team to date, including:
Making a bolt box, costing only €2, whch has led to an annual time
saving equivalent to €624
0 Replacement of valves and gauges in the amine gas system
Clearing out the sand pit that had formed at the base of the machine.
Prior to attention from the TPM team, aptly named the Beach Boys,
sand was dowed to build up to waist height before being cleared. As
well as getting at the source of sand spillage, any surplus sand is swept
away regularly and dropped tools no longer accumulate under the mound
of sand
0 Installation of a blow plate. An initial cost of €50 represents an annual
cost saving of f336

Team achievements
Total cost saving doubling the OEE
0 Average set-up time reduction of 30 minutes per event
0 88 per cent reduction in scrap
The machine will be moved to a location which incorporates bulk storage
of raw materials - a need highlighted by TPM activities. The project will also
address new environmental legslation concerning emissions of the gas used
as a raw material.
The new set-up wiU save hours in changeover times, due to the use of
quick-release fittings and supplier involvement in changeovers, as well as
dramatically reducing leaks.
Valued at €80 000, the project has received f30 000 funding from NSK - a
testament to its commitment to the work of the Beach Boys team.

Quotable quotes

The key to TPM is making it easy to do things right and difficult
to do things wrong.
John Smith, Team Leader, Machine Shop
Ask the operator to get involved in maintenance and there will